US7982845B2 - Display device with sufficient adhesive strength for sealing material - Google Patents
Display device with sufficient adhesive strength for sealing material Download PDFInfo
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- US7982845B2 US7982845B2 US12/379,106 US37910609A US7982845B2 US 7982845 B2 US7982845 B2 US 7982845B2 US 37910609 A US37910609 A US 37910609A US 7982845 B2 US7982845 B2 US 7982845B2
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- sealing material
- liquid crystal
- display device
- crystal display
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- 239000000853 adhesive Substances 0.000 title claims abstract description 63
- 230000001070 adhesive effect Effects 0.000 title claims abstract description 63
- 239000003566 sealing material Substances 0.000 title abstract description 210
- 239000000758 substrate Substances 0.000 claims abstract description 173
- 239000004973 liquid crystal related substance Substances 0.000 claims abstract description 162
- 239000000463 material Substances 0.000 claims abstract description 73
- 230000002093 peripheral effect Effects 0.000 claims abstract description 25
- 239000011347 resin Substances 0.000 claims description 10
- 229920005989 resin Polymers 0.000 claims description 10
- 238000000016 photochemical curing Methods 0.000 claims description 6
- 239000011521 glass Substances 0.000 description 118
- 238000005520 cutting process Methods 0.000 description 56
- 238000004519 manufacturing process Methods 0.000 description 49
- 238000000034 method Methods 0.000 description 37
- 238000001723 curing Methods 0.000 description 21
- 230000004048 modification Effects 0.000 description 13
- 238000012986 modification Methods 0.000 description 13
- 239000010408 film Substances 0.000 description 8
- 238000007789 sealing Methods 0.000 description 8
- 230000003247 decreasing effect Effects 0.000 description 6
- 238000009413 insulation Methods 0.000 description 4
- 239000004065 semiconductor Substances 0.000 description 4
- 239000010409 thin film Substances 0.000 description 4
- 229920001187 thermosetting polymer Polymers 0.000 description 3
- 238000005401 electroluminescence Methods 0.000 description 2
- 230000000903 blocking effect Effects 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
Images
Classifications
-
- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1339—Gaskets; Spacers; Sealing of cells
-
- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/133351—Manufacturing of individual cells out of a plurality of cells, e.g. by dicing
Definitions
- the present invention relates to a display device, and more particularly to a technique which is effectively applicable to a TFT-type liquid crystal display device.
- the TFT-type liquid crystal display device has been used as a display of portable electronic equipment such as a mobile phone terminal, an external display of a television receiver set, a personal computer (PC) or the like.
- portable electronic equipment such as a mobile phone terminal, an external display of a television receiver set, a personal computer (PC) or the like.
- PC personal computer
- the TFT-type liquid crystal display device is a display device which includes a TFT liquid crystal display panel in which a liquid crystal material is filled between a pair of substrates.
- a liquid crystal material is filled between a pair of substrates.
- the pair of substrates is adhered to each other using an annular sealing material (adhesive material), and the liquid crystal material is hermetically filled in a space defined by the pair of substrates and the sealing material.
- the liquid crystal display panels are manufactured by a method which is referred to as a “multi-piece simultaneously forming method” using a large area of mother glass in general.
- a first mother glass from which only a large number of substrates each of which constitutes one of the pair of substrates are formed and a second mother glass from which only a large number of substrates each of which constitutes the other of the pair of substrates are formed are adhered to each other using the sealing material and, thereafter, the first mother glass and the second mother glass are divided into the individual liquid crystal display panels by cutting.
- a method of filling a liquid crystal material is roughly classified into a method of filling a liquid crystal material in a state where two mother glasses are adhered to each other (liquid-crystal dropping filling method (ODF method)) and a method of filling a liquid crystal material after the mother glasses are divided into individual liquid crystal display panels.
- ODF method liquid-crystal dropping filling method
- a size of a portion of the substrate outside a display region has been remarkably decreased. Accordingly, a size (a width) of the sealing material whish is formed outside the display region is also decreased.
- the sealing material is printed on a surface of the first mother glass, the liquid crystal material is dropped, the second mother glass is adhered to the first mother glass, and the sealing material is cured. Accordingly, when a dropping quantity of the liquid crystal material exceeds a predetermined quantity, for example, an excess quantity of liquid crystal material leaks and intrudes into a contact interface (adhering surface) between the second mother glass and the sealing material thus easily giving rise to a drawback that an adhesive strength between the second mother glass and the sealing material is lowered.
- a display device which includes: a first substrate on which a predetermined integrated circuit is formed; a second substrate which is arranged on one surface of the first substrate in an overlapping manner; and an adhesive material which is arranged between the first substrate and the second substrate and has an annular planar shape as viewed from the surface of the first substrate, the adhesive material being provided for adhering the first substrate and the second substrate, an outer periphery of the adhesive material as viewed from the surface of the first substrate includes a zone which is constituted of a plurality of first portions passing substantially the same position as an outer periphery of the surface of the first substrate and a plurality of second portions each of which is connected with the two neighboring first portions and has a center portion thereof in a peripheral direction retracted toward an inner peripheral side of the adhesive material as viewed from the surface of the first substrate.
- the adhesive material is configured such that a distance between the first portion and an inner periphery of the adhesive material as viewed from the surface of the first substrate is longer than a distance between the center portion of the second portion in the peripheral direction and the inner periphery of the adhesive material as viewed from the surface of the first substrate.
- the surface of the first substrate has an approximately rectangular shape, and the zone exists on portions of the outer periphery of the adhesive material which extend along two respective sides of the outer periphery of the surface of the first substrate which are arranged parallel to each other.
- external connection terminals of the integrated circuit are arranged along one side of the outer periphery of the surface of the first substrate, and the zone of the adhesive material exists on portions of the outer periphery of the surface of the first substrate which extend along two respective sides of the first substrate which are connected with the side of the first substrate along which the external connection terminals are arranged.
- the plurality of second portions exhibits a substantially same retracting quantity from the outer periphery of the first substrate at the center portion of the second portion in the peripheral direction.
- the two neighboring second portions differ from each other in a retracting quantity thereof from the outer periphery of the first substrate at the center portion in the peripheral direction.
- a size of the first portion in the peripheral direction and a size of the second portion in the peripheral direction are substantially equal to each other.
- a size of the first portion in the peripheral direction is set larger than a size of the second portion in the peripheral direction.
- the adhesive material is a photo-curing resin.
- the adhesive material has a closed annular planar shape as viewed from the surface of the first substrate.
- the adhesive material has an open annular planar shape as viewed from the surface of the first substrate.
- the display panel is a liquid crystal display panel in which a liquid crystal material is filled between the first substrate and the second substrate.
- an area of the adhesive interface between the first substrate and the adhesive member (sealing material) and an area of the adhesive interface between the second substrate and the adhesive member in the zone of the adhesive material can be increased and hence, it is possible to ensure a sufficient adhesive strength. Accordingly, it is possible to reduce peeling of the adhering surface between the first substrate and the adhesive material and peeling of the adhering surface between the second substrate and the adhesive material.
- the display device of the invention by forming the second portions in the zone of the adhesive material, it is possible to reduce cutting failures when the sides of the first substrate and the second substrate along which the zone of the adhesive material extends are cut.
- FIG. 1A is a schematic front view showing one example of the schematic constitution of a conventional liquid crystal display panel
- FIG. 1B is a schematic cross-sectional view showing one example of the cross-sectional constitution taken along a line A-A′ in FIG. 1A ;
- FIG. 1C is a schematic cross-sectional view showing one example of the cross-sectional constitution taken along a line B-B′ in FIG. 1A ;
- FIG. 2A is a schematic front view showing one example of a manufacturing method of liquid crystal display panels by a multi-piece simultaneously forming method
- FIG. 2B is a schematic enlarged front view showing a region R 3 in FIG. 2A in an enlarged manner
- FIG. 2C is a schematic cross-sectional view showing one example of the cross-sectional constitution taken along a line C-C′ in FIG. 2B ;
- FIG. 3 is a schematic front view for explaining drawbacks of the conventional liquid crystal display panel
- FIG. 4A is a schematic front view showing one example of a printing method of a sealing material in the manufacturing method of liquid crystal display panels of one specific embodiment according to the invention
- FIG. 4B is a schematic enlarged front view showing one example of a planar shape of the sealing material after the pair of mother glasses of this embodiment is adhered to each other;
- FIG. 4C is a schematic front view showing a region which is cut out as one piece of liquid crystal display panel and one example of the planar shape of the sealing material on a periphery of the region;
- FIG. 4D is a schematic enlarged front view showing one example of the constitution of an outer peripheral portion of the liquid crystal display panel obtained by the manufacturing method of this embodiment;
- FIG. 4E is a schematic front view showing one example of the planar constitution of one piece of liquid crystal display panel cut out from the mother glass;
- FIG. 4F is a schematic cross-sectional view showing one example of the cross-sectional constitution taken along a line D-D′ in FIG. 4D ;
- FIG. 4G is a schematic cross-sectional view showing one example of the cross-sectional constitution taken along a line E-E′ in FIG. 4D ;
- FIG. 5A is a schematic front view showing a first modification of the printing method of the sealing material
- FIG. 5B is a schematic front view showing a first modification of the planar shape of the sealing material after curing when the sealing material is printed as shown in FIG. 5A ;
- FIG. 6A is a schematic front view showing one typical example of the planar shape of the sealing material after curing in the manufacturing method of the liquid crystal display panel of the above-mentioned embodiment
- FIG. 6B is a schematic front view showing a second modification of the planar shape of the sealing material after curing
- FIG. 6C is a schematic front view showing a third modification of the planar shape of the sealing material after curing
- FIG. 6D is a schematic front view showing a fourth modification of the planar shape of the sealing material after curing
- FIG. 7A is a schematic front view showing one example of the schematic constitution of the whole mother glass immediately after adhering the pair of mother glasses in a first application example of the manufacturing method of liquid crystal display panels of the above-mentioned embodiment;
- FIG. 7B is a schematic enlarged front view showing a region R 5 shown in FIG. 7A in an enlarged manner
- FIG. 7C is a schematic front view showing one example of the schematic constitution of one piece of liquid crystal display panel obtained by adopting the first application example.
- FIG. 8 is a schematic front view for explaining a second application example of the manufacturing method of liquid crystal display panels of the above-mentioned embodiment.
- FIG. 1A to FIG. 1C are schematic views showing one example of the schematic constitution of a conventional display panel which is provided for explaining a display panel according to the invention.
- FIG. 1A is a schematic front view showing one example of the schematic constitution of the conventional liquid crystal display panel.
- FIG. 1B is a schematic cross-sectional view showing one example of the cross-sectional constitution taken along a line A-A′ in FIG. 1A .
- FIG. 1C is a schematic cross-sectional view showing one example of the cross-sectional constitution taken along a line B-B′ in FIG. 1A .
- the invention is applicable to, for example, a miniaturized liquid crystal display panel used in a liquid crystal display of a mobile phone terminal.
- the liquid crystal display panel used in the liquid crystal display of a conventional mobile phone terminal includes, for example, as shown in FIG. 1A to FIG. 1C , a TFT substrate 1 , a counter substrate 2 , a liquid crystal material 3 , a sealing material (adhesive material) 4 , a lower polarizer 5 and an upper polarizer 6 .
- the TFT substrate 1 includes, for example, an integrated circuit forming layer 102 on a surface (a surface facing the counter substrate 2 ) of an insulation substrate 101 formed of a glass substrate or the like.
- an integrated circuit forming layer 102 for example, a plurality of scanning signal lines, a plurality of video signal lines, TFT elements, pixel electrodes, an alignment film and the like are formed.
- external connection terminals for inputting signals which are applied to the plurality of scanning signal lines, the plurality of video signal lines and the like are arranged in a region R 2 of the TFT substrate 1 .
- semiconductor chips such as driver ICs are mounted in a region R 2 of the TFT substrate 1 .
- the counter substrate 2 includes, for example, a thin film layer 202 on a surface (a surface facing the TFT substrate 1 ) of an insulation substrate 201 formed of a glass substrate or the like.
- a light blocking film referred to as a black matrix in general
- a black matrix which divides a display region DA into individual pixel regions, color filters, an alignment film and the like are formed.
- the combination of the constitution of the integrated circuit forming layer 102 of the TFT substrate 1 and the constitution of the thin film layer 202 of the counter substrate 2 in the liquid crystal display panel according to the invention may take any combination. That is, in the liquid crystal display panel according to the invention, a counter electrode which forms a pair with the pixel electrode in driving the liquid crystal material 3 may be formed on the integrated circuit forming layer 102 or may be formed on the thin film layer 202 . Further, in the liquid crystal display panel according to the invention, the TFT element may adopt the bottom gate structure in which a semiconductor layer is arranged on a gate electrode as viewed from the insulation substrate 101 , or the top gate structure in which the gate electrode is arranged above the semiconductor layer as viewed from the insulation substrate 101 .
- the sealing material 4 is provided for hermetically sealing the liquid crystal material 3 in a space defined between the TFT substrate 1 and the counter substrate 2 .
- a planar shape of the sealing material 4 when the liquid crystal display panel is viewed from a front side thereof is formed in a closed annular shape which surrounds the display region DA as shown in FIG. 1A , for example.
- the sealing material 4 is, for example, made of a photo-curing resin or a thermosetting resin, and is adhered to a surface of the TFT substrate 1 and a surface of the counter substrate 2 .
- the liquid crystal display panel is a transmissive liquid crystal display panel or a transflective liquid crystal display panel
- the lower polarizer 5 is adhered to a back surface (a back surface of a surface facing the counter substrate 2 ) of the TFT substrate 1
- the upper polarizer 6 is adhered to a back surface (a back surface of a surface facing the TFT substrate 1 ) of the counter substrate 2
- a one-layered or a plural-layered phase difference sheet may be interposed between the TFT substrate 1 and the lower polarizer 5 as well as between the counter substrate 2 and the upper polarizer 6 .
- the lower polarizer 5 is unnecessary, and a reflective film is formed on the integrated circuit forming layer 102 in place of the lower polarizer 5 , for example.
- FIG. 2A to FIG. 2C are schematic views showing one example of a manufacturing method of the liquid crystal display panels according to the invention.
- FIG. 2A is a schematic front view showing one example of the manufacturing method of liquid crystal display panels by a multi-piece simultaneously forming method.
- FIG. 2B is a schematic enlarged front view showing a region R 3 in FIG. 2A in an enlarged manner.
- FIG. 2C is a schematic cross-sectional view showing one example of the cross-sectional constitution taken along a line C-C′ in FIG. 2B .
- the x direction and the y direction in FIG. 2A and FIG. 2B are respectively equal to the x direction and the y direction in FIG. 1A .
- the liquid crystal display panels are manufactured by a method which is referred to as “multi-piece simultaneously forming method”.
- a first mother glass 7 from which a plurality of TFT substrates 1 can be formed and a second mother glass 8 from which a plurality of counter substrates 2 can be formed are adhered to each other using the sealing material 4 and, thereafter, the first mother glass 7 and the second mother glass 8 are cut so as to divide these mother glasses 7 , 8 into individual liquid crystal display panels.
- the first mother glass 7 and the second mother glass 8 are cut at portions thereof (cutting lines SL 1 , SL 2 ) where a bold broken line passes, 24 pieces of liquid crystal display panels having a size Lx in the x direction and a size Ly in the y direction can be obtained from one set of mother glasses 7 , 8 .
- the second mother glass 8 (counter substrate 2 ) is, for example, cut along a cutting line SL 3 shown in FIG. 2B so as to expose a region where the external connection terminals of the TFT substrate 1 are arranged or a region where semiconductor chips are mounted.
- the example shown in FIG. 2A to 2C is one example of a case in which a liquid crystal material is filled by a liquid crystal dropping sealing method (ODF method).
- ODF method liquid crystal dropping sealing method
- the liquid crystal material 3 is dropped in each region which is surrounded by the sealing material 4 formed on the region of the first mother glass 7 to be cut out as the TFT substrate 1 .
- the second mother glass 8 is arranged on the first mother glass 7 and the sealing material 4 is cured thus adhering the first mother glass 7 and the sealing material 4 to each other and, at the same time, adhering the second mother glass 8 and the sealing material 4 to each other.
- This step is carried out in a vacuum atmosphere, for example.
- the sealing material 4 is made of a photo-curing resin
- a light having a predetermined wavelength for example, ultra violet lays
- the sealing material 4 is heated at a predetermined temperature so that the sealing material is cured.
- FIG. 2A to FIG. 2C is only an example of the case in which the liquid crystal display panels are manufactured by a multi-piece simultaneously forming method. That is, in actually manufacturing the liquid crystal display panels by the multi-piece simultaneously forming method, the number of the liquid crystal display panels is not limited to 24, and the larger number of (for example, 416 pieces of) liquid crystal display panels may be manufactured from the pair of mother glasses 7 , 8 .
- a size of an outer peripheral portion (a picture frame portion) of the display region DA in the region to be cut out as one piece of liquid crystal display panel for example, a distance FW between a right-side edge of the display region and the cutting line is depicted as if the distance has a large size.
- the distance FW between the right-side edge of the display region DA and the cutting line in an actual liquid crystal display panel is extremely small compared to a size DAW of the display region DA in the x direction.
- the size (the distance FW) of the picture frame portion is decreased, and the size (the distance FW) is, for example, merely approximately 1.35 mm. Further, it is necessary to form the sealing material 4 in the picture frame portion having such a size of approximately 1.35 mm.
- FIG. 3 is a schematic front view for explaining drawbacks of the conventional liquid crystal display panel.
- FIG. 3 is a schematic enlarged front view in which a region R 4 in FIG. 2B is enlarged. Further, the x direction and the y direction shown in FIG. 3 are respectively equal to the x direction and the y direction in FIG. 2B .
- the sealing material 4 is, for example, as shown in FIG. 3 , formed between the cutting line SL and an edge portion of the display region DA (a picture frame portion).
- the distance FW between the cutting line SL 2 and the edge portion of the display region DA is, as previously described, approximately 1.35 mm, for example.
- the sealing material 4 is formed such that a distance W 1 between an inner periphery of the sealing material 4 and the edge portion of the display region DA becomes approximately 0.4 mm, for example.
- a distance W 2 between an outer periphery of the sealing material 4 and the cutting line SL 2 in each liquid crystal display panel is set larger than a value of one half of the cutting tolerance ⁇ SL.
- a size W 3 of the sealing material 4 in the x direction in FIG. 3 becomes approximately 0.85 mm, for example. Further, although not shown in the drawing, a size of the sealing material 4 in the direction perpendicular to the cutting line SL 1 (or SL 2 ) in other portion of the sealing material 4 also becomes approximately 0.85 mm.
- the picture frame portion becomes narrow and, at the same time, an area of an adhering surface between the TFT substrate 1 and the sealing material 4 and an area of an adhering surface between the counter substrate 2 and the sealing material 4 become small thus making it difficult to ensure a sufficient adhesive strength. Accordingly, in the liquid crystal display panel used in the mobile phone terminal, for example, the adhering surface between the TFT substrate 1 and the sealing material 4 is easily peeled and, at the same time, the adhering surface between the counter substrate 2 and the sealing material 4 is easily peeled.
- liquid crystal dropping sealing method when a quantity of liquid crystal material 3 dropped in a region surrounded by one sealing material 4 exceeds a predetermined quantity, when the first mother glass 7 and the second mother glass 8 are adhered to each other, an excess quantity of liquid crystal material 3 intrudes into a contact interface between the second mother glass 8 and the sealing material 4 , for example. In this case, the area of the adhering surface between the second mother glass 8 (counter substrate 2 ) and the sealing material 4 is further decreased and hence, the adhering surface between the counter substrate 2 and the sealing material 4 is more easily peeled off.
- FIG. 4A to FIG. 4G are schematic views for explaining one specific embodiment of the manufacturing method of the liquid crystal display panels according to the invention.
- FIG. 4A is a schematic front view showing one example of a printing method of the sealing material in the manufacturing method of liquid crystal display panels of one specific embodiment according to the invention.
- FIG. 4B is a schematic enlarged front view showing one example of a planar shape of the sealing material after the pair of mother glasses of this embodiment is adhered to each other.
- FIG. 4C is a schematic front view showing a region which is cut out as one piece of liquid crystal display panel and one example of the planar shape of the sealing material on a periphery of the region.
- FIG. 4D is a schematic enlarged front view showing one example of the constitution of an outer peripheral portion of the liquid crystal display panel obtained by the manufacturing method of this embodiment.
- FIG. 4A is a schematic front view showing one example of a printing method of the sealing material in the manufacturing method of liquid crystal display panels of one specific embodiment according to the invention.
- FIG. 4B is a schematic enlarged front view showing one example of a planar shape of the sealing material after the pair of mother glasses of this embodiment is adhere
- FIG. 4E is a schematic front view showing one example of the planar constitution of one piece of liquid crystal display panel cut out from the mother glass.
- FIG. 4F is a schematic cross-sectional view showing one example of the cross-sectional constitution taken along a line D-D′ in FIG. 4D .
- FIG. 4G is a schematic cross-sectional view showing one example of the cross-sectional constitution taken along a line E-E′ in FIG. 4D .
- FIG. 4A and FIG. 4B show the planar constitution of a region corresponding to the region R 4 shown in FIG. 2B .
- FIG. 4C shows the planar constitution of a region corresponding to a region R 3 in FIG. 2A .
- FIG. 4D shows a region on a left side of a cutting line in FIG. 4B which is the schematic enlarged front view.
- FIG. 4E shows a liquid crystal display panel which is formed by cutting out a center portion in FIG. 4C which is the schematic front view.
- the x direction and the y direction in FIG. 4A to FIG. 4E are respectively equal to the x direction and the y direction shown in FIG. 2B .
- the general steps of the manufacturing method of liquid crystal display panels according to the invention are equal to the steps of the conventional manufacturing method of liquid crystal display panels. Accordingly, in this embodiment, only points which make the manufacturing method of the liquid crystal display panels of the invention differ from the conventional manufacturing method of the liquid crystal display panels are explained. Further, in this embodiment, as the conventional manufacturing method of liquid crystal display panels, the manufacturing method which seals the liquid crystal material 3 by a liquid crystal dropping sealing method is exemplified.
- the pair of mother glasses that is, the first mother glass 7 from which plural pieces of TFT substrates 1 can be formed and the second mother glass 8 from which plural pieces of counter substrates 2 can be formed is prepared.
- any one of combinations respectively applied to the conventional liquid crystal display panels may be selected.
- any one of methods which are adopted by the conventional manufacturing method of liquid crystal display panels may be selected in conformity with the constitution of the TFT substrate 1 and the constitution of the counter substrate 2 .
- the sealing material 4 (adhesive material) is formed on the respective regions which are cut out as the TFT substrates 1 from the first mother glass 7 .
- the sealing material 4 forms, besides an annular sealing material 4 a which surrounds the display region DA which is formed also in the conventional manufacturing method, a plurality of island-shaped sealing materials 4 b which passes between the sealing materials 4 a formed in the regions which are cut out as two neighboring TFT substrates 1 in the x direction.
- the annular sealing materials 4 a and the island-shaped sealing materials 4 b are formed by printing an uncured photo curing resin, for example.
- a width W 3 ′ of the annular sealing material 4 a at the timing of the printing is set smaller than a width W 3 after curing by taking a spreading amount due to the deformation of the sealing material 4 a when the second mother glass 8 is adhered to the first mother glass 7 into consideration.
- a size W 4 of the island-shaped sealing material 4 b in the x direction is set to a value which makes the island-shaped sealing material 4 b united with the annular sealing materials 4 a arranged on both sides of the island-shaped sealing materials 4 b due to the deformation of the sealing materials 4 a , 4 b when the second mother glass 8 is adhered to the first mother glass 7 .
- a size W 5 ′ of the island-shaped sealing material 4 b in the y direction can be arbitrarily set, a gap W 6 ′ between two neighboring island-shaped sealing materials 4 b is set to a value which prevents two sealing materials 4 b from being united with each other when the second mother glass 8 is adhered to the first mother glass 7 .
- Specific examples of these sizes W 5 ′, W 6 ′ are explained later.
- liquid crystal material 3 is dropped in the inside of each of the annular sealing materials 4 a formed in the regions cut out as the TFT substrates 1 from the first mother glass 7 .
- the second mother glass 8 is adhered to the first mother glass 7 , and the sealing materials 4 a , 4 b are cured.
- the sealing materials 4 a , 4 b are deformed due to a dead weight of the second mother glass 8 or a pressure applied from the outside so that the sealing materials 4 a , 4 b are united with each other and, for example, are cured in a state that these sealing materials 4 a , 4 b have a planar shape shown in FIG. 4B .
- the sealing materials 4 a , 4 b are cured in a state that two annular sealing materials 4 a which are formed in the regions cut out as two neighboring TFT substrates 1 in the x direction are connected with each other by the plurality of island-shaped sealing materials 4 b formed between two annular sealing materials 4 a thus forming the integral sealing material 4 .
- the sizes W 4 , W 5 ′ of the island-shaped sealing material 4 and the gap W 6 ′ shown in FIG. 4A are respectively set to values which allow the planar shape of the sealing material 4 when the pair of mother glasses 7 , 8 are adhered to each other to assume the shape shown in FIG. 4B .
- parts to be connected by the island-shaped sealing materials 4 b are, for example, two neighboring annular sealing materials 4 a in the x direction and hence, in the planar shape of the sealing materials 4 after the pair of mother glasses 7 , 8 is adhered to each other, for example, as shown in FIG. 4C , the sealing materials 4 which are respectively formed in the regions cut out as the TFT substrates 1 arranged in the x direction are connected (united) with each other.
- the sizes W 5 ′, W 6 ′ at the time of printing the island-shaped sealing materials 4 b are set such that, in the sealing material 4 after the pair of mother glasses 7 , 8 is adhered to each other (after curing), a size W 5 of a portion in the y direction which connects two annular portions and, a gap W 6 between two connected portions (a size of a space portion in the y direction) satisfy the relationship of W 5 ⁇ W 6 , for example.
- the sizes W 5 ′, W 6 ′ at the time of printing the island-shaped sealing materials 4 b are set such that the size W 5 of the portion in the y direction which connects two annular portions and the gap W 6 between two connected portions respectively take values which are expressed by, for example, 0.1 mm ⁇ W 5 ⁇ 5.0 mm (more preferably 1.0 mm) and 0.1 mm ⁇ W 6 ⁇ 5.0 mm (more preferably 1.0 mm).
- the step in which the second mother glass 8 is adhered to the first mother glass 7 and the sealing material 4 ( 4 a , 4 b ) is cured is carried out in a vacuum atmosphere, for example, wherein the second mother glass 8 is stacked on the first mother glass 7 , the sealing material 4 ( 4 a , 4 b ) and the second mother glass 8 are brought into close contact with each other and a gap between the first mother glass 7 and the second mother glass 8 is set to a predetermined value and, thereafter, a light (for example, ultraviolet lays) having a predetermined wave length is radiated to the sealing material 4 so as to cure the sealing material 4 .
- a light for example, ultraviolet lays
- the liquid crystal display panel used in the mobile phone terminal or the like which has the picture frame portion of a small size (width) FW can also increase an adhesive strength between the first mother glass 7 (TFT substrate 1 ) and the sealing material 4 as well as an adhesive strength between the second mother glass 8 (counter substrate 2 ) and the sealing material 4 .
- the area of the adhering surface between the first mother glass 7 and the sealing material 4 and the area of the adhering surface between the second mother glass 8 and the sealing material 4 are respectively increased by amounts corresponding to the connecting portions, for example, even when a quantity of dropped liquid crystal material 3 exceeds a prescribed value and an excess quantity of the liquid crystal material 3 intrudes between the second mother glass 8 and the sealing material 4 , it is possible to ensure a sufficient adhesive strength.
- the first mother glass 7 and the second mother glass 8 are cut along the cutting lines SL 1 , SL 2 thus dividing these mother glasses 7 , 8 into the individual liquid crystal display panels.
- a boundary (cutting line SL 2 ) of the regions which are cut out as two neighboring TFT substrates 1 in the x direction exhibits a state in which a portion where the sealing material 4 passes and a portion where the sealing material 4 does not pass are alternately arranged.
- an impact which occurs at the time of cutting the sealing material 4 is small so that, for example, it is possible to prevent the occurrence of cutting failures such as a peeling of the adhering surface between the TFT substrate 1 or the counter substrate 2 and the sealing material 4 attributed to such an impact at the time of cutting.
- One piece of liquid crystal display panel obtained by the above-mentioned steps forms, for example, as shown in FIG. 4D to FIG. 4G , on an outer periphery (a side surface) of the sealing material 4 as viewed from a surface of the TFT substrate 1 , a zone which is constituted of a plurality of first portions which passes the same position as outer peripheries of the TFT substrate 1 and the counter substrate 2 , and a plurality of second portions each of which is connected with two neighboring first portions and has a center portion thereof as viewed in a peripheral direction (y direction) retracted toward an inner peripheral side of the sealing material as viewed from the surface of the TFT substrate 1 by a distance W 7 .
- a retracting quantity (distance W 7 ) of the second portion is smaller than a distance W 3 between the second portion out of an outer periphery of the sealing material 4 and an inner periphery of the sealing material (W 7 ⁇ W 3 ).
- the above-mentioned zone exists, for example, as shown in FIG. 4E , on portions which respectively extend along a left side 1 B and a right side 1 C of the TFT substrate 1 which are connected with the side 1 A of the TFT substrate 1 on which the external connection terminals are arranged. Further, a distance W 8 between the first portion out of the outer periphery of the sealing material 4 and the inner periphery of the sealing material 4 is set larger than the distance W 3 between the second portion out of the outer periphery of the sealing material 4 and the inner periphery of the sealing material.
- the portion exhibits a shape in which a portion having the width W 8 and a portion having the width W 3 are alternately arranged.
- the liquid crystal display panel obtained by the manufacturing method of this embodiment can increase the adhesive area between the TFT substrate 1 and the sealing material 4 and the adhesive area between the counter substrate 2 and the sealing material 4 compared to the conventional liquid crystal display panel having the same size as the liquid crystal display panel of this embodiment. Accordingly, the liquid crystal display panel having the picture frame portion of the narrow size FW outside the display region DA also can reduce peeling of the adhering surface between the TFT substrate 1 and the sealing material 4 and peeling of the adhering surface between the counter substrate 2 and the sealing material 4 .
- FIG. 5A and FIG. 5B are schematic views for explaining a first modification of the manufacturing method of liquid crystal display panels of the above-mentioned embodiment.
- FIG. 5A is a schematic front view showing a first modification of the printing method of the sealing material.
- FIG. 5B is a schematic front view showing a first modification of the planar shape of the sealing material after curing when the sealing material is printed as shown in FIG. 5A .
- FIG. 5A and FIG. 5B respectively show the planar constitutions of a region corresponding to the region R in FIG. 2B . Further, the x direction and the y direction in FIG. 5A and FIG. 5B are respectively equal to the x direction and the y direction in FIG. 2B .
- the annular sealing material 4 a which is formed in the region cut out as each TFT substrate is formed by the same method as the conventional manufacturing method, that is, by the method where widths (sizes in the direction perpendicular to the cutting line) of respective portions of the annular sealing material 4 a are made uniform.
- the second mother glass 8 is adhered to the first mother glass 7 and the sealing material 4 is cured, for example, as shown in FIG. 4B , a portion of the annular sealing material 4 a which is brought into contact with the island-shaped sealing material 4 b exhibits a planar shape projecting toward a display region DA side.
- planar shape of the annular sealing material 4 a at the time of printing is not limited to the planar shape shown in FIG. 4A or the planar shape shown in FIG. 5A and can be suitably changed.
- FIG. 6A to FIG. 6D are schematic views for explaining second to fourth modifications of the manufacturing method of liquid crystal display panels of the above-mentioned embodiment.
- FIG. 6A is a schematic front view showing one typical example of the planar shape of the sealing material after curing in the manufacturing method of liquid crystal display panels of the above-mentioned embodiment.
- FIG. 6B is a schematic front view showing a second modification of the planar shape of the sealing material after curing.
- FIG. 6C is a schematic front view showing a third modification of the planar shape of the sealing material after curing.
- FIG. 6D is a schematic front view showing a fourth modification of the planar shape of the sealing material after curing.
- FIG. 6A to FIG. 6D respectively show the planar constitution when a region corresponding to the region R 4 in FIG. 2B is viewed in an expanded manner in the y direction.
- the x direction and the y direction in FIG. 6A to FIG. 6D are respectively equal to the x direction and the y direction in FIG. 2B .
- a size W 5 ′ of the island-shaped sealing material 4 b on the cutting line SL 2 in the y direction and a gap W 6 ′ between the island-shaped sealing materials 4 b on the cutting line SL 2 are substantially equal and, at the same time, sizes and positions as viewed in the x direction of spaces formed in the sealing material 4 after curing are also substantially equal.
- the sealing material 4 after curing for example, as shown in FIG.
- the spaces 9 formed in the sealing material 4 are arranged at an actually cut position even when the displacement between the actually cut position and the predetermined cutting line SL 2 assumes a maximum value. Accordingly, it is desirable to set a size W 9 of the spaces 9 in the x direction larger than the cutting tolerance ⁇ SL in forming the sealing material 4 .
- the adhesive area between the first mother glass 7 (or the second mother glass 8 ) and the sealing material 4 is decreased by an amount corresponding to the size difference and hence, when the spaces 9 are arranged densely, it may be difficult to ensure a sufficient adhesive strength.
- a size W 5 of the above-mentioned first portion in the y direction in the planar shape after curing may be set several times as large as a size W 6 of the above-mentioned second portion (space 9 ) in the y direction in the planar shape after curing. Also in this case, when the spaces 9 are arranged at the actually cut position, the sealing material 4 can be cut easily. Further, by elongating the size W 5 of the first portion, the adhesive areas between the mother glasses 7 , 8 and the sealing material 4 can be enlarged thus increasing the adhesive strength. Accordingly, it is possible to prevent peeling of the adhering surfaces between the mother glasses 7 , 8 and the sealing material 4 attributed to an impact at the time of cutting the sealing material 4 , for example.
- the sealing material 4 may be formed such that positions of spaces 9 a , 9 b , 9 c in the x direction in a planar shape after curing may be displaced from each other by a distance ⁇ x 1 .
- three spaces 9 a , 9 b , 9 c arranged in the y direction are formed as one unit, and the positions of these three spaces 9 a , 9 b , 9 c in the x direction are respectively displaced from each other by the distance ⁇ x 1 .
- the sealing material 4 when the sealing material 4 is cut at a position (for example, along a cutting line SL 2 R) displaced toward a right side of the predetermined cutting line SL 2 , the space 9 a which has the position thereof in the x direction displaced by the distance ⁇ x 1 in the +x direction exists on the cutting line SL 2 R. Accordingly, provided that the sealing material 4 is cut within a range of the cutting tolerance ⁇ SL, the spaces 9 exist on the cutting line at a cycle equal to or less than the distance L and hence, peeling of the adhering surfaces between the mother glasses 7 , 8 and the sealing material 4 attributed to an impact at the time of cutting the sealing material 4 can be reduced.
- the planar shape of the sealing material 4 after curing exhibits the shape shown in FIG. 6C , for example, compared to a case in which the same number of spaces 9 ( 9 a , 9 b , 9 c ) have the shape shown in FIG. 6A , sizes W 4 of the individual spaces 9 ( 9 a , 9 b , 9 c ) in the x direction can be decreased and hence, the adhesive areas between the mother glasses 7 , 8 and the sealing material 4 can be increased by an amount corresponding to the reduction of sizes W 4 . Accordingly, the adhesive strengths between the mother glasses 7 , 8 and the sealing material 4 can be increased thus lowering peeling of the adhering surfaces between the mother glasses 7 , 8 and the sealing material 4 .
- FIG. 7A to FIG. 7C are schematic views for explaining the first application example of the manufacturing method of liquid crystal display panels of the above-mentioned embodiment.
- FIG. 7A is a schematic front view showing one example of the schematic constitution of the whole mother glass immediately after adhering the pair of mother glasses in the first application example of the manufacturing method of liquid crystal display panels of the above-mentioned embodiment.
- FIG. 7B is a schematic enlarged front view showing the region R 5 in FIG. 7A in an enlarged manner.
- FIG. 7C is a schematic front view showing one example of the schematic constitution of one piece of liquid crystal display panel obtained by adopting the first application example.
- the x direction and the y direction in FIG. 7A to FIG. 7C are respectively equal to the x direction and the y direction in FIG. 2B .
- exemplified is the case in which all of the plurality of (24 pieces of) TFT substrates 1 which are cut out from the first mother glass 7 and the plurality of (24 pieces of) counter substrates 2 which are cut out from the second mother glass 8 for forming are arranged on the same direction. That is, to focus on a boundary of the regions which are cut out as two neighboring TFT substrates 1 in the y direction, one TFT substrate 1 has a side 1 A on which the external connection terminals are arranged, and another TFT substrate 1 has a side which faces the side 1 A on which the external connection terminals are arranged.
- Such an arrangement is relevant to the rubbing direction at the time of applying rubbing treatment to the alignment film formed on the surface of the TFT substrate 1 and the alignment film formed on the surface of the counter substrate 2 , for example, and is provided for aligning the rubbing direction of the alignment films of all liquid crystal display panels.
- regions which are cut out as two neighboring TFT substrates 1 in the y direction may be formed as a set, and the side 1 A on which the external connection terminals are arranged and the side which faces the side 1 A may be brought into contact with each other in the boundary between two regions.
- VA method Vertical Alignment method
- an annular portion of the sealing material 4 formed in one region and an annular portion of the sealing material 4 formed in another region can be connected with each other at a plurality of portions.
- the adhesive area between the sealing material 4 and the mother glasses 7 , 8 at a zone which extends along the side 1 A on which the external connection terminals are arranged and the side which faces the side 1 A can be also increased thus further reducing peeling of the adhering surface between the TFT substrate 1 and the sealing material 4 and peeling of the adhering surface between the counter substrate 2 and the sealing material 4 .
- the arrangement of the liquid crystal display panels on each of the pair of mother glasses 7 , 8 adopts such an arrangement, when the mother glasses 7 , 8 are divided into the individual liquid crystal display panels by cutting, the planar shape of the obtained liquid crystal display panel becomes as shown in FIG. 7C , for example. That is, with respect to an outer periphery of the sealing material 4 as viewed in a plan view of the TFT substrate 1 , the zone where the above-mentioned first portions and the above-mentioned second portions are arranged alternately exists in portions which are respectively arranged along three sides 1 B, 1 C, 1 D except for the side 1 A on which the external connection terminals of the TFT substrate 1 are arranged.
- FIG. 8 is a schematic front view for explaining a second application example of the manufacturing method of liquid crystal display panels of the above-mentioned embodiment.
- the manufacturing method of liquid crystal display panels in which the liquid crystal material is filled by a liquid crystal dropping sealing method is exemplified.
- the sealing material 4 of the liquid crystal display panel obtained by such a manufacturing method exhibits a closed annular shape as shown in FIG. 4E , for example.
- the invention is not limited to the manufacturing method of liquid crystal display panels in which the liquid crystal material is filled by a liquid crystal dropping sealing method, and is applicable to a manufacturing method of liquid crystal display panels in which a liquid crystal material 3 is filled in the individual liquid crystal display panels after these liquid crystal display panels are cut out from the mother glasses 7 , 8 .
- the sealing material 4 in the obtained liquid crystal display panel is, for example, as shown in FIG. 8 , formed in an open annular shape, wherein a filling port of the liquid crystal material 3 is formed in a portion of a side 1 D which faces a side 1 A of the TFT substrate 1 on which external connection terminals are formed.
- the filling port formed in the sealing material 4 is sealed by another resin material 10 after filling the liquid crystal material 3 , for example.
- the manufacturing method of liquid crystal display panels having such constitution for example, by printing the sealing material 4 on the surface of the first mother glass 7 and by adhering the second mother glass 8 to the first mother glass 7 in the manner described in conjunction with the above-mentioned embodiment, the contact areas between the mother glasses 7 , 8 and the sealing material 4 can be increased. Accordingly, peeling of the adhering surface between the first mother glass 7 (TFT substrate 1 ) and the sealing material 4 and peeling of the adhering surface between the second mother glass 8 (counter substrate 2 ) and the sealing material 4 attributed to an impact at the time of cutting the first mother glass 7 and the second mother glass 8 , for example, can be reduced.
- the manufacturing method of liquid crystal display panels in which the liquid crystal material 3 is filled in the space defined between the pair of substrates (TFT substrate 1 and the counter substrate 2 ) is exemplified.
- the invention is not limited to such a manufacturing method of liquid crystal display panels, and is also applicable to a manufacturing method of liquid crystal display panels in which a first substrate and a second substrate are adhered to each other by an annular sealing material (adhesive material) which surrounds a display region such as a self-luminous-type display panel using an organic EL (Electro-Luminescence), for example.
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Abstract
Description
Claims (12)
Priority Applications (3)
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US13/067,579 US8274635B2 (en) | 2008-02-14 | 2011-06-10 | Display device with sufficient adhesive strength for sealing material |
US13/572,795 US8441607B2 (en) | 2008-02-14 | 2012-08-13 | Display device with sufficient adhesive strength for sealing material |
US13/868,448 US8665412B2 (en) | 2008-02-14 | 2013-04-23 | Display device with sufficient adhesive strength for sealing material |
Applications Claiming Priority (3)
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JP2008-032563 | 2008-02-14 | ||
JP2008/032563 | 2008-02-14 | ||
JP2008032563A JP5408642B2 (en) | 2008-02-14 | 2008-02-14 | Display device |
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US13/067,579 Continuation US8274635B2 (en) | 2008-02-14 | 2011-06-10 | Display device with sufficient adhesive strength for sealing material |
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US20090207370A1 US20090207370A1 (en) | 2009-08-20 |
US7982845B2 true US7982845B2 (en) | 2011-07-19 |
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US13/067,579 Active US8274635B2 (en) | 2008-02-14 | 2011-06-10 | Display device with sufficient adhesive strength for sealing material |
US13/572,795 Active US8441607B2 (en) | 2008-02-14 | 2012-08-13 | Display device with sufficient adhesive strength for sealing material |
US13/868,448 Active US8665412B2 (en) | 2008-02-14 | 2013-04-23 | Display device with sufficient adhesive strength for sealing material |
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US13/067,579 Active US8274635B2 (en) | 2008-02-14 | 2011-06-10 | Display device with sufficient adhesive strength for sealing material |
US13/572,795 Active US8441607B2 (en) | 2008-02-14 | 2012-08-13 | Display device with sufficient adhesive strength for sealing material |
US13/868,448 Active US8665412B2 (en) | 2008-02-14 | 2013-04-23 | Display device with sufficient adhesive strength for sealing material |
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US20110242474A1 (en) * | 2008-02-14 | 2011-10-06 | Hitachi Displays, Ltd. | Display device with sufficient adhesive strength for sealing material |
US20160266435A1 (en) * | 2015-03-09 | 2016-09-15 | Boe Technology Group Co., Ltd. | Display q_panel, display panel and manufacturing method thereof, and display apparatus |
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Also Published As
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US20130235319A1 (en) | 2013-09-12 |
US20110242474A1 (en) | 2011-10-06 |
US20120314176A1 (en) | 2012-12-13 |
US8274635B2 (en) | 2012-09-25 |
JP2009192756A (en) | 2009-08-27 |
JP5408642B2 (en) | 2014-02-05 |
US20090207370A1 (en) | 2009-08-20 |
US8441607B2 (en) | 2013-05-14 |
US8665412B2 (en) | 2014-03-04 |
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